Wall panel construction



y 29, 1956 L. E. BROBERG V 2,747,703

WALL PANEL CONSTRUCTION Filed March 29, 1952 2 Sheets-Sheet 1 o o o o 137 g I :65 1\ 3 45 45 I 1 4/1 I E 'o' 1 I I E I z I E 44 5 L 5/ INVENTORLeona rd iBraberg QYIMVAa A ATTORNEYS.

May 29, 1956 E. BROBERG WALL PANEL CONSTRUCTION 2 Sheets-Sheet 2 FiledMarch 29. 1952 W R 7 00 Y Z w mB m WE I'm L w a Y B ATTORNEYS.

United States Patent WALL PANEL CONSTRUCTION Leonard E. Broberg,Milwaukee, Wis., assignor to A. 0. Smith Corporation, Milwaukee, Wis., acorporation of New York 1 Application March '29, 1952, Serial No.279,409

2 Claims. (Cl. 189-34) The present invention relates to buildingstructures and more particularly to a new improvement in wallconstruction.

One object of the present invention is to provide a building structureof a character whereby substantially all of its parts may beprefabricated in the manufacturing plant and the structure may beassembled at the building site with a minimum of labor.

Another object is to provide a wall structure which may be expedientlyand inexpensively assembled or disassembled by the purchaser or user.

Still another object is to provide a wall construction of a characterwhereby a good many of the parts are of substantially similarconstruction in order to facilitate production.

Another object is to provide a wall construction which may beconveniently packed into a minimum of space to facilitate shipment tothe consumer.

The present invention is directed to a novel all-metal wall constructionwhich is made from a number of standardized parts and is partiallyassembled or prefabricated in the manufacturing plant so that thestructure may be conveniently erected with the use of a few simpletools.

Under the wall construction of the present invention, the supportingmembers, which include a foundation beam, a ceiling beam and a pluralityof vertical connecting studs, are each formed with diverging flanges orsurfaces which are complemented by the converging side flanges of aplurality of locking channels. A plurality of wall panels havinginwardly bent edge portions are disposed against the supporting membersto form the walls of the structure with the bent edges being interposedbetween a diverging flange of the supporting members and thecomplementary converging flange of the channel. By securing the web ofthe locking channel to the supporting member, the channel is wedgedinwardly against the diverging surface of the supporting member toprovide a tight effective attachment of the panel between the convergingand diverging surfaces.

Other objects and advantages will appear in the course of the followingdescription.

Figure '1 is 'an elevational view illustrating the wall structure of thepresent invention with parts being broken away;

Fig. 2 is a horizontal sectional view taken along line 2--2 of Figure 1showing the attachment of the wall panels to the studs;

Fig. 3 is a section on the line 3-3 of Figure 1 showing a stud attachedto the ceiling beam;

Fig. 4 is a vertical sectional view taken along line 44 of Figure 1showing the attachment of the wall panels to the foundation and ceilingbeams;

Fig. 5 is a section similar to the upper end of Fig. 4, some parts beingomitted and others shown in exploded position;

Fig. 6 is an exploded transverse sectional view of a vertical joint; and

Fig. 7 is a perspective view of a corner of a panel.

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Referring to the drawings there is illustrated an embodiment of thepresent invention comprising an all-metal wall structure I mounted on asuitable foundation 2.

The lower portion of the wall structure comprises a foundation beam orchannel 3 having a generally U- shaped cross section which rests on thefoundation 2 with the open side of the U-shaped beam facing thefoundation. Beam 3 extends the entire length of the wall structure 1 andeach leg of beam 3 adjacent the foundation is formed with a reverse bendto provide an outwardly diverging surface 4, and an inwardly extendingbase surface 5 which rests on foundation 2.

The Web 6 of beam 3 is formed with a series of independent slots 7, eachof which extends lengthwise along web 6, and a plurality of annularopenings 8 longitudinally aligned with slots 7 and disposed near theends of the beam.

A plurality of spaced tie rods 9 are employed to secure foundation beam3 to foundation 2. The lower portions of the tie rods are embedded inthe foundation and the rods extend upwardly through the foundation andwithin beam 3 with the threaded upper ends thereof projecting throughthe respective openings 8 or through slots 7 in web 6 of the beam.

The lower portion of each rod 9 may be bent outwardly away from the wallstructure and the lower end thereof may be provided with a head andwasher 10 embedded in the foundation to firmly attach rod 9 tofoundation 2.

The threaded end of each rod 9 which projects upwardly through web 6 ofbeam 3 is received by a suitable washer 11 and engaged by nuts 12 tofirmly secure beam 3 to the foundation.

Vertically extending studs 13 are disposed on the web 6 of foundationbeam 3 and extend upwardly therefrom.

Studs 13 include a pair of spaced side plates 14 with each vertical edgeportion of plates 14 being bent outwardly, at an angle of approximately45, to provide each plate with a pair of diverging flanges 15 The spacedside plates 14 are joined at their upper extremities by the horizontallydisposed flat plate 16 which is edge welded to the web portions 17 ofthe side plates. A fiat base plate 18 similarly connects the side plates14 at the lower extremities thereof and rests on web 6 of foundationbeam 3. A pair of bolts 19 are employed to secure studs 13 to beam 3 andextend downwardly through suitable aligned openings in the base plate 18and in web 6. Nuts 20 threaded on the lower end of bolts 19 secure thestuds to beam 3.

To provide the studs with added strength and rigidity, a plurality ofspaced tie plates 21 are welded edgewise between the side plates 14.

A ceiling beam 22, which corresponds to foundation beam 3 in order toachieve a standardization of parts in manufacture, is disposed on thetop of the spaced studs 13. The open side of ceiling beam 22 facesupward and the web portion 23 thereof is in contacting relation with thefiat plates 16 of the series of spaced studs 13.

Ceiling beam 22 is secured to each of the top plates by a pair of bolts24 as shown in Fig. 3 which extend upwardly through suitably alignedopenings in web 23 and plate 16 and are secured by threaded nuts 25located inside beam 22.

Web 23 of beam 22 is provided with a number of longitudinal slots 26 asshown in Fig. 3 similar to slots 7 in beam 3. The slots 26 and 7 in therespective beams 3 and 22 permit access to the interior. of the wallstructure for- However, panels 27 may merely be 3 secured to the beams 3and 22 or to the studs 13 depending on the strength requirement of thestructure.

As shown in the drawings the wall structure comprises an interior andexterior wall surface. However it is contemplated that the structure mayconsist of only one wall surface depending on the ultimate use of thestructure. The panels 27 are constructed of lightweight sheet metal and,if a corrosive medium is to be encountered in service, all, or aportion, of the panels may be glass-coated or constructed of acorrosion-resistant material.

As shown in Fig. 6 the top, bottom and side edge portions of each panel27 are inwardly oifset from the main panel surface 28 to provide aperipheral surface 29 which is substantially parallel to the main panelsurface, and a connecting beveled or oblique surface 36, both of whichextend completely around the panel.

The beveled connecting surface 30 affords a space saving when the panelsare nested or stacked for shipment, as all parts of one panel willcontact the corresponding parts of the adjacent panel with no lost spacetherebetween.

The peripheral surface 29 adjacent the top of each panel 27 is disposedflatwise against the side surface of ceiling beam 22 and the peripheralsurface 29 adjacent the bottom of each panel is similarly disposedagainst the side surface of foundation beam 3.

The vertical side edges of adjacent panels are in a spaced relation onweb 17 of stud side plates 14 with the peripheral surface 29 adjacentthe side edges of each panel being disposed flatwise against web 17.

The surface 30 adjacent the side edges of each panel is designed to bein contacting relation and complement the respective diverging flanges15 of the studs.

A plurality of resilient plastic or rubber seals 31 may be interposedbetween the overlapping surfaces 29 of panels 27 and between the sidesurfaces of the respective beams 3 and 22 to form a seal between panel27 and the beams.

A plurality of horizontal base locking channels 32 and ceiling lockingchannels 33 are employed to secure the lower and upper portions of theinterior and exterior wall panels 27 to the respective foundation beam 3and ceiling beam 22. As the channels 32 and 33 are of identicalstructure and are similarly employed on the wall structure, thefollowing description will be directed merely to the base channel 32.

The base channels 32 are horizontally disposed end-toend, the numberemployed depending on the length of the wall structure, within thelongitudinal recess bounded by the lower beveled surface 30 of panels 27and the outwardly diverging surface 4 of foundation beam 3. The openside of base channel 32 faces inwardly toward beam 3 and the web 34 ofthe channel is substantially flush with the main panel surface 28.

The edge portions of base channels 32 are bent inwardly to an angle ofapproximately 45 to form flanges 35 and 36 with the upper convergingflange 35 complementing beveled surface 39 and the lower convergingflange 36 complementing the outwardly diverging surface 4 of beam 3. Theconverging flanges 35 and 36 of channels 32 are cushioned from therespective underlying complementary surfaces 30 and 4 by a seal 37. Seal37 is preferably constructed of a resilient material such as plastic orrubber. Seals 37 extend the entire length of the channel 32 and theinner longtitudinal edges of each seal may be bent around thelongitudinal edge of each respective channel flange 35 and 36 so as tobe co-extensive therewith. The outer longitudinal edge of the seal maybe formed with a greater thickness than the remainder of the seal toprovide a smooth joint between the main panel surface 28 and the web 34of channel 32.

Channels 32 are attached to beam 3, with the intermediate beveledsurface 30 of panels 27 being secured therebetween, by a plurality ofspaced screws 38. The screws extend inwardly through suitable alignedopenings in the webs 34 of channels 32 and in beams 3 and cooperate withnuts 39. Nuts 39 are secured against rotation when receiving screws 38by suitable nut retainers 40.

As screws 38 are threaded into nuts 39 channels 32 are wedged againstthe diverging surfaces 4 and 30 to firmly secure the panels 27 to beams3.

A plurality of vertical locking channels 41 having the same structure ashorizontal channels 32 and 33 extend from channels 32 to channels 33 andare employed to secure the interior and exterior panels to therespective studs. 13.

The channels 41 are disposed within the vertical recesses formed betweenthe beveled surfaces 30 of adjacent panels with the open side of channel41 facing stud 13 and the web 42 of the channel being in a substantiallyflush relation with the main panel surface 28.

Each of the converging side flanges 43 of channels 41, as shown in Fig.6, is disposed flatwise against the respective beveled surfaces 30 ofthe adjacent panels and separated therefrom by plastic seal 44 similarin structure to seal 37.

The marginal offset surface 29 of panel 27 is disposed flatwise againstweb 17 of stud side member 14 and prevents the beveled surface 30 of thepanel from pulling out from between the diverging flange 15 of sidemember 14 and the complementary converging side flange 43 of channel 41.

Channels 41 are attached to studs 13 similarly to the manner by whichchannels 32 are secured to beam 3. A plurality of screws 45 extendinwardly through aligned openings in web 42 of channel 41 and sidemember 14 between the spaced vertical edges of adjacent panels 27 andcooperate with fixed nuts 46 which are secured behind the screw openingsby nut retainers 47.

The converging side flanges of channels 32, 33 and 41 are of lesserwidth than the complementary stud and beam surfaces against which theside flanges are disposed. This difference in width permits the sideflanges to be wedged against the complementary surfaces until a snug fitis obtained therebetween, thus eliminating the necessity for preciselymachined surfaces and close tolerances between the two adjoiningelements.

The bands or seals 48 which correspond to seals 31 are interposedbetween stud 13 and surfaces 29 and 30 of panel 27. Bands 48 preventforeign matter from accumulating within the respective channels, andalso provide a cushion and seal between the open end of the channels andthe adjacent element.

A suitable ceiling or roof, not shown, may be secured to ceiling beam 22by a plurality of tie rods 49. The lower end of each rod 49 extendsthrough an opening 50 or through slot 26 in web 23 of beam 22 and isengaged by a washer 51 and nut 52. The upper end of each rod 49 may thenbe secured to a suitable roof which will rest on beam 22.

The preferred method of assembly is to initially construct the studs 13in the manufacturing plant. This is accomplished by welding base plate18, top plate 16 and tie plates 21 edgewise between side members 14.

Foundation 2 is constructed in the field and is of the configuration ofthe structure. Tie rods 9 are partially embedded in the foundation andare spaced so that the projecting ends thereof register with theopenings 8 in the web 6 of foundation beam 3 which is to be subsequentlydisposed on the foundation.

Beam 3 is placed on the foundation with the upper ends of rods 9projecting upwardly through openings 8 and the beam is secured to thefoundation 2 by threading home the nuts 12.

The prefabricated studs 13 are then vertically disposed in a spacedrelation on foundation beam 3 and base plates 18 of studs 13 are securedto web 6 of beam 3 by bolts 19.

Ceiling beam 22 is disposed on the top of spaced studs 13 with web 23thereof being secured to top plate 16 of the studs by bolts 24.

Before disposing panels 27 on the wall structure nuts 39 are attachedbehind the screw openings in beam 3 and beam 22 by nut retainers 40 andare in position to subsequently receive screws 38. Nuts 46 are similarlyfixed behind the screw openings in side plates 14 of studs 13 by nutretainers 47.

The panels 27 are then properly disposed on the wall structure withseals 31 and 48 interposed between the panel surfaces and the adjoiningbeam and stud surfaces, to provide interior and exterior wall surfaces,or a single wall surface, as desired.

The horizontal locking channels 32 and 33, having the longitudinal edgesthereof covered by seal 37, are positioned on the structure and attachedto the respective beams 3 and 22 by screws 38 which cooperate with nuts39.

The assembly is completed by attaching the vertical channels 41 to thestuds 13 by the screws 45 which engage the fixed nuts 46 with the seals44 being interposed between the channels and panels 27.

The present invention provides a sturdy wall structure which may bequickly and inexpensively assembled by the consumer. In addition aminimum of parts are employed and these, as far as practical, are ofstandardized construction to facilitate production and erection. Forexample, of the basic elements employed, beams 3 and 22 are identicalstructures, channels 32, 33 and 41, are all of like construction and maybe employed interchangeably and panels 27 are all standard and may beinterior or exterior wall surfaces.

Various embodiments of the present invention may be employed within thescope of the following claims.

I claim:

1. An all-metal building structure, comprising an open sided foundationchannel resting on the foundation of the structure with the open side ofsaid channel facing said foundation and with the sides of said channelbeing substantially flat and turned outwardly adjacent the foundation toform a pair of diverging flanges, an open sided ceiling channel disposedabove said foundation channel with the open side of said ceiling channelfacing upwardly and with the sides of said channel being substantiallyflat and turned outwardly adjacent said open side to form a pair ofdiverging flanges, a plurality of laterally spaced studs extendingvertically between the foundation and ceiling channels and secured tothe web of each channel, a plurality of wall panels to form the wallsurfaces of the structure and having a generally rectangular main panelsurface bounded by an inwardly diverging section and terminating in aperipheral edge section which is inwardly offset from and parallel tothe main panel surface, and said offset edge section adjacent the top ofthe panels being disposed flatwise against the side of the ceilingchannel and the offset edge section adjacent the bottom of said panelsbeing disposed flatwise against the side of the foundation channel,means securing the vertically extending edge section of the wall panelsto said studs a plurality of horizontally extending foundation lockingchannels having converging side flanges with the uppermost side flangethereof being disposed flatwise over the lowermost diverging surface ofsaid panels and with the lowermost side flange being disposed flatwiseagainst the diverging flange of the foundation channel, a plurality ofhorizontally extending ceiling locking channels having converging sideflanges with the uppermost of the ceiling locking channel side flangesbeing disposed flatwise against the diverging flange of the ceilingchannel and the lowermost of said ceiling locking channel side flangesbeing disposed flatwise against the upper diverging section of saidpanels, and securing means extending through said channels and attachingthe locking channels to the respective foundation and ceiling channelsand firmly securing said panels between the locking channels and therespective foundation and ceiling channels.

2. An all metal building structure, comprising an open sided foundationchannel resting on the foundation of the structure with the open side ofsaid channel facing the foundation and with the sides of said channelbeing substantially flat and turned outwardly adjacent the foundation toform a pair of diverging flanges, an open sided ceiling channel disposedabove the foundation channel with the open side of said channel facingupwardly and with the sides of said channel being substantially flat andturned outwardly adjacent said open side to form a pair of divergingflanges, a plurality of laterally spaced stud plates extendingvertically between the foundation and ceiling channels and joining saidchannels together with the vertical edge portions of said ceiling andfoundation stud plates being turned outwardly from a central web to forma pair of diverging flanges, a plurality of wall panels providing thewall surface of the structure and having a generally rectangular mainpanel surface bounded horizontally and vertically by an intermediatesection diverging toward said channels and to an outer edge section withthe latter section being inwardly olfset and parallel to the main panelsurface, the horizontal offset edge section adjacent the top of eachpanel being disposed flatwise against the side of the ceiling channeland the horizontal edge section adjacent the bottom of each panel beingdisposed flatwise against the side of the foundation channel, and thevertical offset edge sections on each side being disposed flatwiseagainst the web of a stud plate, a plurality of horizontal extendingfoundation locking channels having converging side flanges with theuppermost flange of each locking channel being disposed flatwise overthe lowermost diverging section of said panels and with the lowermostflange of each locking channel being disposed flatwise against adiverging flange of the foundation channel, a plurality of ceilinglocking channels having converging side flanges with each uppermostceiling channel locking flange being disposed flatwise against thediverging flange of the ceiling channel and each lowermost ceilinglocking channel flange being disposed flatwise against the upperdiverging section of said panels, a vertical locking channel for eachstud plate with converging side flanges on each vertical locking channeldisposed complementary to the diverging flanges of the stud plate andwith the vertical diverging section of each panel being interposedbetween a converging flange of each vertical locking channel and adiverging flange of each stud plate, and securing means extendingthrough the locking channels and foundation and ceiling channels andstud plates to firmly secure the wall panels between the lockingchannels and said foundation and ceiling channels and stud plate.

References Cited in the file of this patent UNITED STATES PATENTS742,873 Jamieson Nov. 3, 1903 1,295,368 Pilkington Feb. 25, 19192,065,531 Kerr Dec. 29, 1936 2,140,709 Mauser Dec. 20, 1938 2,145,469Weinland Jan. 31, 1939 2,263,510 Lindsay Nov. 18, 1941 2,347,756 SwensonMay 2, 1944 2,376,728 Shaer May 22, 1945 2,519,162 Tucker Aug. 15, 1950FOREIGN PATENTS 395,098 Great Britain of 1933

